Remove/install cylinder head

AR01.30-T-5800BB

Remove/install cylinder head

14.2.12

 

Remove/install

1.1

Open left rear maintenance flap

Model 671 with engine 457.942

1.2

Open liftgate

Model 613 with engine 457.944

2

Remove interior flap above engine

Model 671

AR88.40-T-1100-03AA

Model 613 with engine 457.944

AR88.40-T-1100-03BA

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

3

Drain coolant



*BF20.00-N-1001-01D



Notes on coolant

AH20.00-N-2080-01A

 Danger!

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

4

Disconnect electric cables at battery

Model 671

AR54.18-T-0002AA

Model 613

AR54.18-T-0002BA



Notes on battery

AH54.10-P-0001-01A

5.1

Remove air filter housing

Model 613

AR09.10-T-1150C

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

6

Remove engine brake valve fitting

Model 671

AR14.15-T-6302AA

Model 613

AR14.15-T-6302BA

7

Remove air intake hose

Model 671

AR09.10-T-8030AA

Model 613

AR09.10-T-8030BA

8.1

Remove bottom charge air pipe on left

Model 671

AR09.41-T-1316AA

9

Remove turbocharger

Model 671

AR09.40-T-6020AA

Model 613

AR09.40-T-6020BA

10

Remove exhaust manifold

Model 671

AR14.10-T-3915AA

Model 613

AR14.10-T-3915BA

11

Remove charge air manifold

AR09.41-T-8681BB

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

12

Remove MR/PLD injection lines

AR07.15-T-9235BB

13

Remove cylinder head cover

Model 671

AR01.20-T-5014AA

Model 613

AR01.20-T-5014BA

14

Remove fuel leak line (9)

 Installation: Install new sealing rings (8). The connections of the line fittings must be aligned.



*BA01.30-N-1005-01J

15.1

Unscrew pressure line constant throttle (6) at cylinder 6 and remove from cylinder head (15)

 Only if constant throttle is installed.

 Installation: Replace sealing rings (5).



*BA01.30-N-1004-01J

16.1

Detach coolant vent line (3)

Model 613 only

 Installation: Install new sealing rings (2).



*BA01.30-N-1003-01J

17

Remove rocker arm assembly (11) and valve bridges (13)

AR05.00-T-5521BB

18

Remove tappet rods (12)

 Installation: Oil bearing sockets and ball heads of tappet rods with engine oil. Ensure tappet rods are correctly seated in the tappets.

19

Remove cylinder head bolts (14) and cylinder head (15)

 Always place cylinder head down to the side when injection nozzle installed. The injection nozzle projects at the bottom of cylinder head.

 Installation: Lightly oil cylinder head bolts. Pay attention to tightening instructions when tightening cylinder head bolts.

AR01.30-T-5800-07BB



*BA01.30-N-1001-01J

20

Take cylinder head gasket (16) off crankcase

 Installation: Clean sealing surfaces. Lay new cylinder head gasket (16) over the fitting sleeves (17). The part number of the cylinder head gasket (16) must point upwards. Pay attention to thickness of the cylinder head gasket (16).



Checking

21

Check contact surface for cylinder head for damage and corrosion

 Face-grind in the case of a complaint.

AR01.30-T-7162BB

22

Check contact surface for cylinder head over the whole length and diagonal for flatness

 Check ontact surface for cylinder head with knife-edge straightedge over entire length and diagonally for flatness. There must not be any light gap visible. The specified permissible variation is merely a reference value and cannot be measured.

*BE01.40-N-1001-02I

Straightedge

If damage is present:

Face grind contact surface of cylinder head

AR01.30-T-7162BB

23

Inspect flatness of cylinder head (15)

AR01.30-T-5800-12BB

*BE01.30-N-1002-02K

Straightedge

24

Inspect length of shank of cylinder head bolts (14), install new cylinder head bolts if necessary

*BE01.30-N-1001-01H

25

Install in the reverse order

 Installation: Steps 20 - 1.

Number

Designation

Engine 457.9

BE01.30-N-1001-01H

Cylinder head bolts
M152

Shank length

mm

212

Number

Designation

Engine 457.9

BE01.30-N-1002-02K

Permissible variation in flatness of lower contact surface in a longitudinal direction

Over a length of 150 mm

mm

0.015

Number

Designation

Engine 457.9

BE01.40-N-1001-02I

Crankcase - flatness of contact surface

over a length of 170 mm in longitudinal and transverse direction

mm

0.02

Number

Designation

Engine 457.9

BA01.30-N-1001-01J

Cylinder head bolt to crankcase

Stage 1

Nm

10

Stage 2

Nm

50

Stage 3

Nm

100

Stage 4

Nm

200

Stage 5

°

90

Stage 6

°

90

See picture

-̧

BA01.30-N-1002-01J

Connection fitting, coolant vent line to cylinder head

Nm

35

BA01.30-N-1003-01J

Banjo bolt, coolant vent line to connection fitting

Nm

35

BA01.30-N-1004-01J

Banjo bolt, constant throttle pressure line to cylinder head

Nm

45

BA01.30-N-1005-01J

Banjo bolt, fuel leak line to cylinder head

Nm

15

Number

Designation

Engines 402.970, 441.980, 446.938, 457.944

Engine
457.942

BF20.00-N-1001-01D

Filling capacity for coolant

without VOITH retarder

Liters

75 to 100

76 to 92

with VOITH retarder

Liters

95 to 120

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-02A

BB00.40-P-0325-02A